SOS Fluid Analysis: Maintenance Products & Services

Maintenance Products & Services
SOS Fluid Analysis

September 18, 2020 1
Fluid Analysis Program
Maintenance
Management
 Over 30 years of SOS Oil Analysis Success

 Lab Tests Selected by Caterpillar Engineers to Determine
Condition of Engines & Components
September 18, 2020 Slide No 2

What do you already know about S•O•S Services?
Maintenance
Management
 What is it?
 Who uses it?
 Who provides the service?
 How much is charged for the service?
 Who are the competitors?
 What is its value to Caterpillar and the Dealers?
 How do we use S•O•S Services internally?
 Why do customers use it?
 What are our goals?
 What are the opportunities and obstacles?

Maintenance
Management
S•O•S SM - a proprietary process used by Caterpillar dealers to monitor

the impact of maintenance program, application and operational factors
on product health. Customers provide descriptions along with oil and
coolant samples on a regular basis.
The dealer S-O-S Analyst utilizes label input, lab data, local knowledge
and an arsenal of support resources to provide users proactive operating
cost reduction recommendations. This process can also aid in "root
cause" determination if a product problem exists.
Over 30 Years of S•O•S

Proper Oil Sampling
Maintenance
Management
 For best results you must follow proper sampling procedures

using one of the following two methods:
 Oil Valve Probe (Preferred Method)

 Vacuum Extraction
Vacuum Probe

Proper Oil Samples
Maintenance
Management
 Obtain Good Representative Samples

 Fully Complete Sample Bottle Label
 Submit Samples Promptly
 Sample at Proper Intervals
 Consistent and Sequential Samples

Improper Sampling
Maintenance
Management
 Do Not Take Oil Samples From:
 Oil Drain Stream
 Oil Drain Pan
 Used Filter

Need for Additional Samples
Maintenance
Management
 To check for oil transfer
 Verify trend
 To acquire a baseline "Sample"
 Suspect Original Sample was contaminated
 Too small volume original sample

Use Separate Pumps
Maintenance
Management
 For Oil Samples

 For Coolant Samples

Performance Guarantee
Maintenance
Management
 You Will Get
 Accurate Analysis
 Quick Results
 Expert Data Evaluation
 Clear Recommendations
 Follow Up
 Maintenance Solutions

Owner Benefits
A Valuable Management & Condition
Maintenance
Management
Monitoring Tool
 Early problem detection

 Shortened repair time
 Scheduled downtime
 Better parts & personnel availability
 Life Cycle Management
 Maintenance Monitoring
 Increased value of Used Equipment

SOS Oil Analysis
Maintenance
Management
 Focus on Both:
 Condition of Oil and Condition of

Equipment
 Four SOS Oil Analysis Aspects:
 Wear Rate Analysis

 Oil Condition Analysis
 Oil Cleanliness Analysis
 Fuel, Water or Glycol & ELC
Detection

The 3 key aspects of the program
Maintenance
Management
Communication
Technical Interpretation

Wear Rate Analysis
Maintenance
Management
 Tracks and quantifies wear

elements
 Charts rate of wear
element increase
 Wear trending
 Element combinations
allows for component
specific interpretation

Wear Rate Analysis
Maintenance
Management
 Spectrophotometry (AA, ICP, or DCP)
 Quantifies metal wear elements from components in "Parts / Million" (PPM)
 Copper, Iron, Chrome, Lead, Tin,
Aluminum, Molybdenum
 Qualifies wear rate trends
40
The “Bathtub” curve
35
30
25
Run-in wear Degradation
PPM
20
15
10
5
0
Ti me
Component Hours
Wear Metals Analyzed
Maintenance
Management
 Wear Level Norms - Model/Compartment

Wear Tables
 Wear Meals: Copper (Cu), Iron (Fe),
Chromium (Cr), Lead (Pb), Tin (Sn),
Aluminium (AI) and Molybdenum (Mo)
 Dirt Entry: Silica (Si)
 Water Entry: Sodium,Potassium (Na,K)
 Classic Combinations
 Oil Add Pack Elements
 Calcium, Magnesium, Zinc & Phosphorus

Classic Wear Elements
Maintenance
Management Primary Secondary Potential Wear Probable Problem Area/Causes
Engines Element Element
Silicon Iron, Chrome, Liners, Rings, Air Induction System/Filter Dirt
Top End
(Dirt) Aluminium Pistons Contamination
Iron Chrome, Aluminium Liners, Rings, Abnormal Operating Temps,Oil
Pistons Degradation, Fuel and/or Coolant
Contamination, Storage (Rust)
Chrome Molybdenum, Rings, Pistons Blowby, Oil Consumption, Oil
Aluminium Degradation
Iron Liners, Gears, Abnormal Operating Temps, Lack
Valve Train, of Lubrication, Contamination,
Engines Crankshaft Storage (Rust)
Bottom End Silicon Lead, Aluminium Bearings Dirt Contamination
(Dirt)
Lead Aluminium Bearings Lack of Lubrication, Coolant
Contamination, Fuel
Hydraulics Contamination
Silicon Molybdenum, Cylinders, Rods Dirt Contamination
(Dirt) Aluminium
Copper Iron Hydraulic Pumps Oil Degradation, Contamination
Transmissions
Aluminium Iron, Copper Liners, Gears, Abnormal Operating Temps, Lack
Valve Train, of Lubrication, Contamination,
Crankshaft Storage (Rust)
Copper Iron Liners, Gears, Abnormal Operating Temps, Lack
Final Drives Valve Train, of Lubrication, Contamination,
Crankshaft Storage (Rust)
Silicon Iron, Aluminium Gears Dirt Contamination, Clay Soils
(Dirt) Contamination
Iron Sodium, Chrome Gears, Bearings Water Entry, Preload Loss

Oil Condition Analysis
Maintenance
Management
 Infrared Analysis Uses Optical Wave
Lengths to Evaluate Changes in the
Oil:
 Compares Old to New Oil
 Assures the oil in use is still protecting
your equipment
 Infrared Analysis Determines levels of

:
 Oxidation
 Soot Level
 Sulfation
 Nitration
 Also Kinematic Viscosity Test

Oil Condition Analysis - Oxidation
Maintenance
Management
 Conditions that increase Oxidation

 High operating temperature
 Extended oil usage
 Depleted antioxidant additives
 Glycol and Copper contamination

Oil Condition Analysis - Soot
Maintenance
Management
 Soot Thickens Oil & Shortens Engine Life

Through Ineffective Lubrication
 Conditions that Cause Soot

 Plugged Air Filter Element
 Excessive Idling
 Cool Engine Temperatures
 Blow-by
 Excessive/Rapid Acceleration

Oil Condition Analysis - Sulphur & Nitrates
Maintenance
Management
 Infrared Analysis also Detects:

 Sulfur Products
 Nitration
Both can cause corrosive wear

Oil Condition Analysis - Water, Glycol or Fuel
Maintenance
Management
Separate Test for Each:
 Water: Less than 0.5%
 Glycol & ELC: Any amount

(Extended Life Coolant)
 Fuel : Less than 4%

Oil Cleanliness Analysis
Maintenance
Management
 70% - 85% of Hydraulic

failures are caused by
contaminants
 Early contaminant warning

is imperative

Maintenance
Management
 Uses Particle Count (PC)

 Counts by size range
all particles present in
the oil (metallic or not)
 Detects Additional Signs of
Abnormal Wear
 Used for Non-Engine
compartments
 Metallic & Nonmetallic
particles counted

Oil Cleanliness - ISO Code Rating System
Maintenance
Management
 Standard method of measuring Particle Count

oil cleanliness Size Categories
> 2 Microns
 Quantifies matter by size > 5 Microns
> 10 Microns
 Expresses Particle Count test > 15 Microns

results as ISO Code > 25 Microns
> 50 Microns
> 75 Microns
> 100 Microns

ISO Code Rating System
 ISO …International Standards Organization
Maintenance
Management
 ISO Code Numbers represent particles in a ml. of fluid
 Ranges
 Smaller Code Number = Fewer Number of Particles
Example: ISO Code 16

Each ml. of fluid contains between
320 and 640 particles

Oil Cleanliness - ISO Code Rating System
Maintenance
 ISO 4406 Code Levels (example):
Management
 Two-Factor Code (X/Y)

 (X) Represents Number of Particles Particle Quantity Range
Larger than 5 Microns Code Minimum Maximum
 (Y) Represents Number of Particles
Larger than 15 Microns 11 10 20
12 20 40
 >5 and >15 Micron Sizes
13 40 80
 Example: 16/14 14 80 160
400 particles > 5 Microns
100 particles > 15 Microns
15 160 320
16 320 640

Maintenance
Management
Cleanliness analysis may help detect potential

failures which other tests may have not detected
•gear failures
•roller bearing failures
•sleeve bearings
•synthetic materials
Can be supplemented by
microscopic observation

Cleanliness targets
Maintenance
Management Fill oils (FD, Trans., Hydraulic System)
ISO 16/13 or cleaner
Cat machine Roll Off Cleanliness

Hydraulic Systems (implement & steering):
Power Train / Transmission Systems*:
*exceptions exist: ISO 18/15 for a number of
models
Reconditioned / rebuilt components

Clean up to “roll off” levels
What’s Normal?
Maintenance
Management
We Screen Data Three Ways:
 By obvious contamination
or serious wear
 By the trend of each

compartment's data history
 By comparing data
trends of similar units

Trending…
Maintenance
Management
 TRENDING …
 Is the Basis for Oil Interpretation Accuracy

SwOwS Sample Process
Maintenance Machine
Management
Sample
Fuel Water ICP Particle Count I.R
TECHNICAL
EVALUATION
Fax SOS REPORT

SAMPLE DATA
TAKDJFAKJDFKJDFASKJDFLSDKJFADKLJ
AKDJFALKSDJFASKLDJFASKDJFDKJ
SDKJKSJFKDSJ
SKDJFSAKDJFASKLDJFASDKLJFSKLADJF
Phone
AKSDJFASKLDFJASKLDFJSDKLJFSLKDJDD
ADFASDJFKSDJFKDSJFKDSJFDKDFD
Report
ADFHASKDJFKLASDJFSDKJFDKJFDKJFDKJ
AKSDJFKASJFAKSJFKDSJFSDKJFKSJFKJF
SDFASFASDFASDFASDFASGDFGDSFGHDFH
SDFASDFASDFASFSADFASDFSFSFSDFSD
ASDFASDFSADFASDFSDAFSDFSDFSDFSAD
SDFAFDAS SDFASDFASD DSFASDF

ADFSDFFD ADSFASDFDS SDAFASF
ASDFASFA ADFASDFASD DSFASDF
Site
Project Mgr
Mail Email
Data
Action Trend Graphs

SOS Fluid Analysis Report EQUIP. # WL701
JOBSITE * BIG SUMP
MAKE CAT
Henry Walker Contracting P/L MODEL 994
Maintenance
Management Att: Mr Alan Carson SERIAL No. 9YF00040
PO Box 294 COMPARTMENT PUMP DRIVE
Cloverdale OIL BRAND & TYPE BELRAY TL4
WA 6105 OIL CHGD? Y
ORDER No. YANDI
LABEL # 13-45
LAB.I.D. # 96X52691
EVALUATION CODE B
Date
Taken ELEMENT ELEVATED - POSSIBLY DUE TO DIRTY ENTRY.PRATICLE COUNT RESULTS
12/12/1996 OIL TOTAL HOURS TO BE ADDED WHEN AVAILABLE.
ADDED HOURS ON OIL CHECK SEALS AND BREATHERS FOR DIRT ENTRY POINTS. CHECK MAGNETIC
CURRENT PLUG FOR EXCESSIVE FERROUS METAL. OIL CHANGED AT THIS SERVICE.
REC'D
181296 N 19850 324
A E
Date
Taken ELEMENT ELEVATED - POSSIBLY DUE TO DIRTY ENTRY. PRATICLE COUNT IS HIGH
15-11-96 CHECK SEALS AND BREATHER FOR DIRT ENTRY POINTS.
PREVIOUS POSSIBLE BEARING OR GEAR TRAIN WEAR. CHECK MAGNETIC PLUG FOR
REC'D #1 EXCESSIVE FERROUS METAL. OIL CHANGED AT THIS SERVICE
201196 N 19526 244
Date
Taken IRON IS SLIGHTLY HIGH. ALL OTHER ELEMENTS TEST RESULTS APPER NORMAL.
19-10-96
PREVIOUS POSSIBLE BEARING OR GEAR TRAIN WEAR. CHECK MAGNETIC PLUG FOR FOR
REC'D #2 EXCESSIVE FERROUS METAL. OIL CHANGED AT THIS SERVICE.
251096 N 19282 261
Date
Taken FOR HOURS ON OIL IS SLIGHTLY HIGH. ALL OTHER ELEMENTS TEST RESULTS
06/10/1996 APPEAR NORMAL
PREVIOUS CHECK MAGNETIC PLUG FOR EXCESSIVE FERROUS METAL. OIL CHANGED AT
REC'D #3 THIS SERVICE.
141096 N 19021 279
ELEMENT OIL CONDITION/CONTAMINANTS

CONCENTRATIONS IN PPM % OF ALLOWABLE
DATE CU FE CR PB AL SI MO NA MG SN ZN W F A ST OXI NIT SUL TBN PCT TAN PQ ***
181296 8 389 1 2 32 51 - 13 - CUR 1 - N - - - - - - - - - - -
201196 15 301 2 5 B32 75 - 42 - #1 2 - N - - C- - - D
- - 314 - - -
251096 4 304 1 1 8 18 - 10 - #2 1 - N - - - - - - - 2 - - -
141096 8 211 1 1 7 13 - 11 - #3 1 - N - - - - - - - 14 - - -

Trend Analysis Module (TAM)
Maintenance
Management
 Receive your SOS analysis reports electronically
 Automatically update sample results
 View actual reports or graph results
 Review all your sample results including interpretation
 Prioritize according to Problem Severity Review “Urgent”
Samples First

SOS Program
Maintenance
Management
 Analysis of oil from all systems

 Consider both oil condition and component wear
 Designed for Cat products, but valuable for other makes
 Achieve Cat machine design life
 Reduce operating cost
 Increase the value of your used Cat equipment
 Others make oil recommendations We provide maintenance &
repair recommendations and monitor the condition of
your components
 SOS program success:
A partnership with you.

Fluid Analysis Value
Maintenance
Management
 Significant Returns - Minor

Investment
 Increasing Availability
 Scheduling Repairs
 Reducing Operating Costs
 Obtain Full Design Life
 Increase Value of Used Cat
machines

The Cost of S.O.S
Maintenance
Management

Cat 988B - 15,500 SMU - Final Drives
–Leaking Front RH Final Drive

High Fe & Silicon and PC Warning
–Findings

Seal was Leaking Allowing Water & Dirt to Enter
–Cost

Actual: Bearings & Seals Replaced - $18,800

Potential: Total Rebuild - $35,200 (Estimate)
Savings: $16,400
S.O.S Cost $ 304.00 (38 x $8.00)

The Cost of S.O.S
Maintenance
Management

Cat 320 - 3,700 SMU - Engine
–7 Samples over Last 600 Hrs

Silicon Increasing

Fe Increasing & Last 2 with Urgent Rating
–Findings

Dirt Entry through Faulty Turbo/Air Cleaner Seal
–Cost

Actual: Seal $52.00 - Inc 0.5 hr Labor

Potential: Engine Rebuild - $35,000 (Estimate)
Savings: $34,948
S.O.S Cost $ 136.00 (17 x $8.00)

SOS SAVES CUSTOMERS MONEY
Maintenance
Management
•Worldwide, 4% of the samples analyzed prevent failures
•Assume major failure costs: $ 15,000

•And preventive repair costs: $ 7,000
•Savings for user is: $ 8,000
•Potential savings over 100 samples:

4 x 8,000 = $ 32,000 ---> $ 320 / sample
•Potential saving after 40 samples:

320 x 40 = $ 12,800 minus cost of samples

SOS CUSTOMER BENEFITS
Maintenance
Management
COMPANY SAMPLE ALERTS ALERT AS % SAVES ESTIMATED $ RETURNED

COUNT OF SAMPLES SAVINGS PER SAMPLE
1 2,677 178 6% 22 $119,300 $44.46
2 384 76 15% 68 $19,000 $49.47
3 541 85 15% 15 $53,900 $99.63
4 222 41 18% 3 $8,500 $38.28
5 176 28 15% 7 $19,900 $113.06
6 434 133 30% 10 $40,000 $92.16
7 1,431 372 24% 13 $44,250 $30.92
5,865 913 15% 138 $304,850 $51.97

ADDITIONAL BENEFITS
Maintenance
Management
CUSTOMER NOTATION:
“OUR TOTAL SAVINGS ARE PROBABLY DOUBLE OR

TRIPLE THIS FIGURE WHEN YOU ADD THE:
•PRODUCTION GAINED DUE TO INCREASED UP TIME
•FAILURES AVERTED DUE TO IMPROVED P.M.

INSPIRED BY OIL ANALYSIS MONITORING”

Cat S•O•S Fluids Analysis Opportunity
Maintenance
 6 million samples WW - 20% DCAL WW
Management
 $10.00/sample = $60,000,000 in dealer revenue
 Dealer opportunity is $240,000,000 for CAT equipment alone

for oil samples, coolant sample opportunity at 20% DCAL is
$15,000,000.
 2-2.5% of samples…. average $2500 - 5000 work order
 At current volumes, this represents $375,000,000 - in parts and

service opportunity…Cat and non-Cat
 Reality check, 10-15% of critical CAT samples end-up in dealer

WO’s from S•O•S Services is $33,750,000.
Quinn Co. Example
Maintenance
Management
 213 critical CAT S•O•S samples in 1999 (about 2% of total Cat machine
samples)
 22 created WO’s or 10%
 WO’s generated $213,684.96 (X165 WW Dealers = $35M) - reality

check
 Don’t know how many parts orders are generated
 This is 6% of the total dealer parts and service work
 Information generated from Quinn Co’s. PSSR commissions software

database.

G&R Example
Maintenance
Management  The oil sample volume is 61,809 samples.

 They find 3.3%(2,023 samples) critical samples.
 With a 10% conversion rate, G&R has generated 202 WO’s.
 This is about $505,750 in PS Sales or $8.18 PS Sales / sample.
 Have not been able to quantify parts orders generated.
 70% of the WO’s in the construction division were done on machines using SOSSM
Services.
 Jack Deats, PSSR in Delaware, stated “SOS is involved in 50% of the service work
we bring in”.

Maintenance
Management
Larry Czernik
Caterpillar MPSG
COMMUNICATION IS EVERYTHING !!
Maintenance
Management

SOS Coolant Analysis
Maintenance
Management
 Detects Potential Problems
 Problems in Engine, Transmission & Hydraulic Cooling Systems
 Cooling Systems Problems

Degrade Oil
 Results in Premature
Failure of Critical
Components

S.O.S. Coolant Analysis
Maintenance
Management
 Coolant Requirements of Diesel Engines:
 Diesel Engines Produce

Tremendous Power
 Diesel Engine Oil Transfers

Heat to Coolant
 Coolant Absorbs
Engine, Transmission
and Hydraulic Heat

SOS Coolant Analysis
Maintenance
Management
 Improper Cooling System Maintenance Oxidizes Oil
 Hot Shutdowns Oxidizes Coolant

 Damages Engine Parts

Key Benefits of Coolant Analysis
Maintenance
Management
 Fluid condition
 More vital now: Higher performance systems ….
good heat dissipation is essential
 Reduce risk of component failure

 Half of engine problems
caused or accelerated by
poor cooling system
performance
 Enables before-failure repairs
 Another indicator in the life cycle

management process

SwOwSKCoolant Analysis
 Multi-level analysis
Maintenance
Management
 Field screening
 Cooling system obvious problems awareness
 Generally done by visiting dealer personnel
 Basic tests done with a coolant analysis kit
– Refractometer for glycol %
– Test strips for nitrite check
– pH meter for pH
– Odor and appearance
 Level 1 analysis
 Generally done in a dealer lab
 Every 250 hrs.
 Level 2 analysis
 Generally done in a specialized lab
 Once a year or as indicated by Level I

Maintenance
Management
 Level 1: verification of coolant properties
 Chemistry
 glycol % (refractometer)
 nitrite % (titration)
 water hardness
 acidity (pH meter)
 Conductivity
 total dissolved solids
(conductivity meter)
 Physical attributes
 appearance, color, odor
 foam

 Level 2: coolant properties + cooling system condition complete evaluation
Maintenance
Management
 Engine, transmission, hydraulic cooling system
 Degradation
 hardness
 ammonia level,
 reserve alkalinity
 Chemistry
 source of inhibitor depletion
 source of oxidation products
 source of contaminants (chromatograph)
 corrosion and scaling products identification (spectro)

SOS Fluid Analysis: Maintenance Products & Services

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Maintenance Products & Services

SOS Fluid Analysis

 Over 30 years of SOS Oil Analysis Success

September 18, 2020 Slide No 2

September 18, 2020 Slide No 3

S•O•S SM - a proprietary process used by Caterpillar dealers to monitor

Over 30 Years of S•O•S

 For best results you must follow proper sampling procedures

 Oil Valve Probe (Preferred Method)

September 18, 2020 Slide No 6

 Obtain Good Representative Samples

September 18, 2020 Slide No 7

 Do Not Take Oil Samples From:

 Oil Drain Stream

 Oil Drain Pan

September 18, 2020 Slide No 8

September 18, 2020 Slide No 9

 For Oil Samples

September 18, 2020 Slide No 10

 Expert Data Evaluation

September 18, 2020 Slide No 11

 Early problem detection

September 18, 2020 Slide No 12

 Condition of Oil and Condition of

 Four SOS Oil Analysis Aspects:

 Wear Rate Analysis

September 18, 2020 Slide No 13

September 18, 2020 Slide No 14

 Tracks and quantifies wear

September 18, 2020 Slide No 15

 Wear Level Norms - Model/Compartment

September 18, 2020 Slide No 17

September 18, 2020 Slide No 18

 Infrared Analysis Determines levels of

 Also Kinematic Viscosity Test

September 18, 2020 Slide No 19

 Conditions that increase Oxidation

September 18, 2020 Slide No 20

 Soot Thickens Oil & Shortens Engine Life

 Conditions that Cause Soot

September 18, 2020 Slide No 21

 Infrared Analysis also Detects:

Both can cause corrosive wear

September 18, 2020 Slide No 22

Separate Test for Each:

 Water: Less than 0.5%

 Glycol & ELC: Any amount

 Fuel : Less than 4%

September 18, 2020 Slide No 23

 70% - 85% of Hydraulic

 Early contaminant warning

September 18, 2020 Slide No 24

 Uses Particle Count (PC)

September 18, 2020 Slide No 25

 Standard method of measuring Particle Count

 Expresses Particle Count test > 15 Microns

September 18, 2020 Slide No 26

 ISO Code Numbers represent particles in a ml. of fluid

 Smaller Code Number = Fewer Number of Particles

Example: ISO Code 16

September 18, 2020 Slide No 27

 Two-Factor Code (X/Y)

September 18, 2020 Slide No 28